Useful tools and techniques

[fcel]

Quote from this thread ....
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There was a question how to cut square holes for AC jack and switch. I found the switch that has
the same width as AC jack and I put it directly above the jack so I have to open just one square
hole. Since most of my panels are usually 1/4" doing it by hand would be pretty hard. I used many
different methods before, but found out that those 2 tools are most handy for the job. To start
the hole I drill 1/4" holes in ea. corner of the square. Final trim is done by hand and a file.
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Over the weekend, I have successfully cut a rectangular hole for installing a power switch on a 3/16" Al Sheet Metal per Peter's suggestion of drilling 1/4" hole in the corners. I just want to mention that it can be done by using a jig-saw (for cutting circular holes) with metal blades and it would be helpful if the holes are a little bit bigger than the blades.

Another very helpful suggestion from Peter! Thanks.

[jleaman]

hpotter are you a book worm or do you just try ideas in your head like me ..



J'

[Peter Daniel]

I stopped reading books about 10 years ago. The only things I read now are Nelson Pass' articles and service manuals.
The ideas usually come to my head uninvited.

[PedroPO]

Hpotter:

Kewl set of tools, dude!

What about engraving aluminium pannels?

I'm thinking of engraving some letters (SON OF ZEN, of course)with 1mm depth in a 3mm aluminium front panel.

do you think a router would do the job? will it work in aluminium and with only 1mm depth?

the tricky part is all that curves...

With a ruller and lots of time it could be made, and I could say that I have a HMC (human manual controlled) milling station in my home

[Peter Daniel]

Me, myself wouldnt be so brave. You might waste a pretty good panel that way. Never tried engraving myself, only dry transfer.

[PedroPO]

have you seen that last Zen amp with the big lettering?

I WANT THOSE FOR MEEEEEE!!!! BAAAD!

I'll try first with a small drill with a router acessory.

If fails I'll leave it to the pro's and go for CNC..

[PedroPO]

I found out a techique (just today) to make PCB markings with a laser printer and transparencies. I ran out of transparencies and tried with transparent stickers.

it was awsome! all the lines are firmly attached to the copper, in fact it's very difficult to come off.

Here is the hole thing:

1- make the drawing of the PCB and reverse it (mirror)

2- print it wit laser printer or copier to transparent plastic for laser printer (heat resistent)

3 - position it in the blank PCB

4 - put the iron on it in the oo or ooo
mark and press it against the plate

5 - detach the plastic carefully

6 - sink the pcb in ferric cloride or whatever U use .


I guess it could also work with front pannel lettering.

If my engraving adventure fails I'll try this

[Peter Daniel]

Ive seen it and it looks really cool. Why not trying proffesional services who do engraving, jewelery stores maybe.

[PedroPO]

I dont know why, but have the tendency to try to make everything myself, even if it is more expensive...

[Peter Daniel]

So how come you didn't make your own heat sinks?